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An interior damage free approach for nanosecond pulsed laser ablation of single crystal diamond via metal film induced self-maintaining graphitization 通过金属膜诱导自保持石墨化实现单晶金刚石纳秒脉冲激光烧蚀的内部无损伤方法
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2024-09-26 DOI: 10.1016/j.jmapro.2024.09.083
Nian Liu , Ling Lei , Jingming Zhu , Hao Lu , Junfeng Xiao , Jianguo Zhang , Xiao Chen , Jianfeng Xu , Kazuya Yamamura
When laser ablation was conducted on an uncoated single-crystal diamond (SCD) substrate, interior damage and random ablation were observed. Metal film-induced self-maintaining graphitization (MISG) was proposed as a generic approach to solve this problem. MISG was realized through coating a ∼ 100-nm-thick metal film on an SCD substrate. Experiments involving laser irradiation of metal films, such as Au-, Al-, Ti-, and Pt-coated SCD substrates, revealed that the material removal depths were the same when the output power was the same and that the surface was covered by graphite after laser irradiation. In addition, the laser-induced damage to the upper or lower surface in the case of the uncoated SCD substrate disappeared. A semitransparent model based on Beer-Lambert law and an opaque model based on modified Level-Set method were built to simulate laser irradiation on uncoated and metal–coated SCD substrates. In the case of the uncoated sample, the laser energy was largely absorbed by the areas with high-concentration defects, leading to preferential graphitization. In the case of the metal-coated sample, a graphite layer was thermally induced on the SCD surface via heat transition during the period of laser irradiation of the metal film. Subsequently, the graphite layer was self-maintaining, and the material removal acted like a graphite piston sinking to the interior of the SCD substrate. This study demonstrates the feasibility of MISG as a universal approach for avoiding interior damage during laser ablation of SCD substrates.
在未涂层的单晶金刚石(SCD)基底上进行激光烧蚀时,会出现内部损伤和随机烧蚀现象。金属膜诱导的自保持石墨化(MISG)是解决这一问题的通用方法。MISG 是通过在 SCD 衬底上镀一层厚度为 100 纳米的金属膜来实现的。激光照射金属膜(如金、铝、钛和铂涂层的 SCD 基底)的实验表明,当输出功率相同时,材料去除深度相同,激光照射后表面被石墨覆盖。此外,在未涂层 SCD 衬底的情况下,激光对上表面或下表面造成的损伤消失了。建立了基于比尔-朗伯定律的半透明模型和基于改进的 Level-Set 方法的不透明模型,以模拟未涂层和金属涂层 SCD 基底上的激光照射。在未涂层样品上,激光能量主要被高浓度缺陷区域吸收,从而导致优先石墨化。对于金属涂层样品,在激光照射金属膜期间,通过热转换在 SCD 表面形成了石墨层。随后,石墨层自我保持,材料去除就像石墨活塞下沉到 SCD 基底内部。这项研究证明了 MISG 作为一种通用方法在激光烧蚀 SCD 基底时避免内部损伤的可行性。
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引用次数: 0
Digital twin for weld pool evolution by data-physics integrated driving 通过数据物理集成驱动实现焊池演变的数字孪生
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2024-09-26 DOI: 10.1016/j.jmapro.2024.09.022
Wenhua Jiao , Da Zhao , Xue Mei , Shipin Yang , Xiang Zhang , Lijuan Li , Jun Xiong
Perception of the welding process is a widely recognized challenge in intelligent manufacturing. The critical issue involved is accurately detecting the evolution and state of the weld pool, with the weld backside width being a crucial parameter. A prevalent approach involves training deep learning algorithms with welding process data to uncover latent patterns for predicting the backside width of the weld pool. However, this data-driven method heavily relies on welding process data and label data, which are prone to systematic and cumulative errors during acquisition and fabrication processes. Consequently, traditional regression methods restrict both accuracy and generalization capabilities of these models. To address this limitation, this study proposed a loss function for a regression model estimating weld backside width based on maximum likelihood estimation principles, and prior functions and transfer learning strategies were employed to enhance the prediction accuracy of the regression model. In addition, the weld surface width, arc voltage, and welding current were combined with a simplified heat source model to effectively visualize the cross-section of the weld pool. A digital twin system was developed to record, analyze, and visually characterize weld pool evolution.
对焊接过程的感知是智能制造领域公认的一项挑战。其中涉及的关键问题是准确检测焊池的演变和状态,而焊缝背面宽度是一个关键参数。一种流行的方法是利用焊接过程数据对深度学习算法进行训练,以发现预测焊池背面宽度的潜在模式。然而,这种数据驱动的方法严重依赖焊接过程数据和标签数据,而这些数据在采集和制造过程中容易出现系统误差和累积误差。因此,传统的回归方法限制了这些模型的准确性和泛化能力。针对这一局限,本研究基于最大似然估计原理,为估计焊缝背面宽度的回归模型提出了损失函数,并采用先验函数和迁移学习策略来提高回归模型的预测精度。此外,还将焊缝表面宽度、电弧电压和焊接电流与简化的热源模型相结合,有效地实现了焊池横截面的可视化。我们开发了一个数字孪生系统,用于记录、分析和直观描述焊接熔池的演变。
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引用次数: 0
Thermal-fluid modeling and simulation of Ti-6Al-4V alloy filaments during shaping in the hot-end of material extrusion additive manufacturing 材料挤压增材制造热端成型过程中 Ti-6Al-4V 合金长丝的热流体建模与模拟
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2024-09-25 DOI: 10.1016/j.jmapro.2024.09.040
Gaius Chukwuka Nzebuka , Chukwuzubelu Okenwa Ufodike , Al Mazedur Rahman , Matthew B. Minus , Chijioke Peter Egole
Continuous progress in material extrusion additive manufacturing is motivated by the need to produce functional parts at a low cost for medical, aerospace, and automotive applications. A significant innovation is impregnating a polymeric melt with metal powder (particle) to produce a filament that will be 3D printed using a low-cost desktop printer. The presence of metal particles affects the complex flow dynamic and temperature profile during processing through the hot-end of the 3D nozzle. The current study employs numerical simulation to analyze the effect of powder content on the outlet flow field during the melting of polymer-filled metal filament material extrusion additive manufacturing. Titanium 64-5 filament was experimentally measured to obtain thermophysical properties and another Titanium 64-5 filament thermophysical properties were empirically determined. Each filament was simulated using a finite element method to obtain temperature, viscosity, and shear rate data. A detailed discussion of the implementation of the thermal-fluid model was presented. The results obtained indicate that the two types of filaments' sensitivity to the feeding rates differ at a certain region of the extrusion regime. Also, further simulation was performed to investigate the response of the flow fields with the powder contents. The temperature and viscosity results obtained at the nozzle outlet indicate that at a high powder content, the printing of the polymer-filled metal filament can be performed at a high extrusion rate with possible extrudate shape stability. The thermal-fluid model and simulation can be used for selecting process parameters for any new binder-metal particle formulation.
由于医疗、航空航天和汽车应用领域需要以低成本生产功能部件,材料挤压快速成型技术不断取得进展。一项重要的创新是在聚合物熔体中浸渍金属粉末(颗粒),生产出丝状物,然后使用低成本桌面打印机进行三维打印。金属颗粒的存在会影响三维喷嘴热端加工过程中复杂的流动动态和温度曲线。本研究利用数值模拟分析了聚合物填充金属长丝材料挤出增材制造熔化过程中粉末含量对出口流场的影响。实验测量了钛 64-5 长丝的热物理性质,并根据经验确定了另一种钛 64-5 长丝的热物理性质。使用有限元法对每种长丝进行模拟,以获得温度、粘度和剪切率数据。对热流体模型的实施进行了详细讨论。结果表明,在挤压过程的某个区域,两种长丝对喂料速率的敏感性不同。此外,还进一步模拟研究了流场对粉末含量的响应。在喷嘴出口处获得的温度和粘度结果表明,在粉末含量较高的情况下,聚合物填充金属丝可以在较高的挤出速率下进行打印,并可能保证挤出物形状的稳定性。热流体模型和模拟可用于为任何新的粘合剂-金属颗粒配方选择工艺参数。
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引用次数: 0
An integrated simulation and experimental study of calendering process in water-based manufacturing of lithium-ion battery graphite electrode 锂离子电池石墨电极水基制造中压延工艺的综合模拟与实验研究
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2024-09-25 DOI: 10.1016/j.jmapro.2024.09.076
Yu Wang, Boman Su, Chris Yuan
Lithium-ion batteries produced from water-based manufacturing processes are favored for their environmental and economic advantages, while currently sacrificing some technical performance. This paper reports an integrated study on the calendering process of water-based manufacturing of lithium-ion battery graphite electrode, aiming to improve electrochemical performance of the manufactured lithium-ion batteries. The interactive mechanism between the calendering process and the porous microstructure of the produced graphite electrode was systematically investigated. It reveals that the graphite electrode with 40 % of porosity produced under 79,509 N/m calendering force achieves an optimal 333 mAh/g of specific capacity and 91.2 % of capacity retention after 100 cycles.
水基制造工艺生产的锂离子电池因其环保和经济优势而备受青睐,但目前也牺牲了一些技术性能。本文综合研究了水基制造锂离子电池石墨电极的压延工艺,旨在提高所制造锂离子电池的电化学性能。系统研究了压延工艺与所制石墨电极多孔微结构之间的相互作用机理。结果表明,在 79,509 牛/米的压延力下生产的石墨电极孔隙率为 40%,在 100 次循环后,比容量达到 333 mAh/g,容量保持率达到 91.2%。
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引用次数: 0
Filtered kriging for improved interpolation of periodic manufacturing surfaces 改进周期性制造表面插值的过滤克里金法
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2024-09-25 DOI: 10.1016/j.jmapro.2024.09.002
Zhiqiao Dong , Sixian Jia , Chenhui Shao
High-resolution characterization of surfaces is essential in a variety of quality control tasks in modern manufacturing, such as surface quality inspection and tooling maintenance. However, direct high-resolution surface measurements often come with high cost and/or long measurement time. Interpolation based on spatial process models, especially kriging-type methods, has been used to obtain denser estimations from low-resolution and cheaper measurements. Periodic spatial correlations, which commonly exist in manufacturing applications, cannot be adequately captured by conventional spatial models, thereby causing potential performance degradation or numerical issues. To address these challenges, we propose a new procedure termed as filtered kriging (FK), which separates the periodic component using a bandpass pre-filter, such that the residual can be well fitted with common models. Through frequency-domain analysis, conditions under which FK is effective are identified, and a practical bandpass filter design strategy is devised. A new theorem is proven to show that, when measurements are free from aliasing, perfect reconstruction guaranteed by the Nyquist-Shannon sampling theorem is achieved by FK estimations under certain assumptions. Finally, the effectiveness of FK is demonstrated by case studies using real-world periodic surfaces from two-photon lithography and ultrasonic metal welding. FK is shown to capture spatial correlation more adequately than conventional methods, and achieves better interpolation accuracy.
在现代制造业的各种质量控制任务中,如表面质量检测和模具维护,高分辨率的表面表征是必不可少的。然而,直接进行高分辨率表面测量往往成本高昂,测量时间长。基于空间过程模型的插值法,特别是克里金类型的方法,已被用于从低分辨率和较便宜的测量中获得更密集的估计值。传统的空间模型无法充分捕捉制造应用中普遍存在的周期性空间相关性,从而导致潜在的性能下降或数值问题。为了应对这些挑战,我们提出了一种称为滤波克里金(FK)的新程序,它使用带通预滤波器分离周期性成分,从而使残差可以很好地与普通模型拟合。通过频域分析,确定了 FK 有效的条件,并设计了实用的带通滤波器设计策略。新定理表明,当测量没有混叠时,在某些假设条件下,FK 估计可以实现奈奎斯特-香农采样定理所保证的完美重构。最后,通过使用双光子光刻和超声波金属焊接的实际周期性表面进行案例研究,证明了 FK 的有效性。与传统方法相比,FK 能够更充分地捕捉空间相关性,并实现更好的插值精度。
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引用次数: 0
Achieving excellent properties of laser tailor-welded thin Al-Si coated press-hardened steel joint via controlling dilution rate 通过控制稀释率实现激光定制焊接薄铝硅涂层压硬钢接头的优异性能
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2024-09-25 DOI: 10.1016/j.jmapro.2024.09.065
S. Guo , Z.Q. Jin , Y.Q. Liu , F.R. Wang , Y.Q. Wang , Z.X. Li , H.L. Yi , G.M. Xie
In laser tailor welded traditional 25 μm thick Al-Si coated press-hardened steel (PHS), a lot of ferrite was easily formed in the weld, so filling with expensive high-alloys wire is usually necessary. In this work, a new thin Al-Si coated PHS with 18 μm thickness was laser tailor welded, and a cheap low alloy wire was attempted to fill into the weld to via control the dilution rate. At a high dilution rate of 94%, the weld contained a ferrite fraction of 38%, resulting in the fracture occurring in the weld during tension and bending. At a medium dilution rate of 85%, the ferrite fraction in the weld decreased to 18%, obtaining excellent tensile and bending properties. The tensile strength and elongation of the joint reached 1528 MPa and 5.6%, respectively, with fracture being in the base metal (BM). The maximum bending load and displacement were 1291 N and 7.0 mm, respectively, and cracks initiated and propagated in the BM. This is attributed to the small amount of ferrite and stress concentration in the narrow weld. At a low dilution rate of 76%, the ferrite reduced to 6%, and the bending cracks initiated and propagated in the BM. However, the tensile specimen fractured in the weld, which should be related to the relatively low C concentration and the stress concentration at the weld toe due to the weld reinforcements.
在激光焊接传统的 25 μm 厚的铝硅涂层压硬钢(PHS)时,焊缝中很容易形成大量铁素体,因此通常需要使用昂贵的高合金焊丝进行填充。在这项工作中,对厚度为 18 μm 的新型薄铝硅涂层 PHS 进行了激光定制焊接,并尝试在焊缝中填充廉价的低合金焊丝,以通过控制稀释率来实现。在 94% 的高稀释率下,焊缝含有 38% 的铁素体,导致拉伸和弯曲时焊缝断裂。在 85% 的中等稀释率下,焊缝中的铁素体比例降至 18%,从而获得了优异的拉伸和弯曲性能。接头的拉伸强度和伸长率分别达到了 1528 兆帕和 5.6%,断裂发生在母材(BM)中。最大弯曲载荷和位移分别为 1291 牛顿和 7.0 毫米,裂纹在基体金属中产生并扩展。这归因于窄焊缝中铁素体数量较少和应力集中。在 76% 的低稀释率下,铁素体减少到 6%,弯曲裂纹在 BM 中产生并扩展。然而,拉伸试样却在焊缝中断裂,这应该与相对较低的铁素体浓度以及焊缝加固导致的焊趾处应力集中有关。
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引用次数: 0
Research on manufacturing technology of nanoimprinted grating 纳米压印光栅制造技术研究
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2024-09-25 DOI: 10.1016/j.jmapro.2024.09.033
Jiawei Zhang , Jirigalantu , Shuo Yu , Yilong Wang , Hongzhu Yu , Wenhao Li
In the 1990s, Professor Stephen Chou from Princeton University introduced the concept of nanoimprint lithography, a novel method for manufacturing nanostructures using templates. Grating replication involves using these processed gratings as molds to create replicas. However, traditional grating replication methods are complex and inefficient. By incorporating fast nanoimprinting technology into grating replication, production efficiency can be significantly improved, which is crucial for large-scale grating replication. This article reviews the recent advancements in nanoimprinting for grating preparation both domestically and internationally. It summarizes the development process, identifies the challenges in grating replication technology using nanoimprinting, and anticipates future trends in high-precision grating replication.
20 世纪 90 年代,普林斯顿大学的 Stephen Chou 教授提出了纳米压印光刻技术的概念,这是一种利用模板制造纳米结构的新方法。光栅复制就是利用这些加工过的光栅作为模具来制造复制品。然而,传统的光栅复制方法既复杂又低效。通过将快速纳米压印技术融入光栅复制,可以显著提高生产效率,这对大规模光栅复制至关重要。本文回顾了纳米压印技术在光栅制备方面的国内外最新进展。文章总结了纳米压印技术的发展过程,指出了利用纳米压印技术复制光栅所面临的挑战,并预测了高精度光栅复制的未来发展趋势。
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引用次数: 0
Development of an adaptive smith controller for cutting torque control in a milling process 开发用于铣削过程中切削扭矩控制的自适应史密斯控制器
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2024-09-24 DOI: 10.1016/j.jmapro.2024.09.048
Mao-Qi Hong, Meng-Shiun Tsai
Optimizing the feedrate to regulate cutting force or torque not only enhances machining efficiency but also protects machines against wear and tear. Generally, most of the studies simplified the dynamic model of machining process as a first or second-order transfer functions and the effects of the interpolator and communication dead-time delay of control signals were not included. Neglecting these factors could lead to system instability or oscillations when machining conditions change. In this paper, a comprehensive machining process model that integrates interpolation, servo drive system, cutting model, and communication dead-time delay is developed. To address varying dynamic behaviors under different machining conditions, such as different cutting depths, an adaptive Smith controller was developed. The proposed controller integrates an online parameter estimator and a Smith predictor. The estimated parameter reflected the cutting process dynamics, including the effects of tool wear and system uncertainties. The Smith predictor architecture was used to solve the communication dead-time delay problem, which was neglected in previous studies. The performance of the adaptive Smith controller was experimentally validated on a workpiece with three different cutting depths. Compared to a conventional proportional-integral controller or a Smith predictor, the adaptive Smith controller could adjust the feedrate to maintain a constant torque with less oscillations. The proposed control architecture reduced machining time by 10.5 % compared to an uncontrolled case.
通过优化进给速度来调节切削力或扭矩,不仅能提高加工效率,还能保护机床免受磨损。一般来说,大多数研究都将加工过程的动态模型简化为一阶或二阶传递函数,没有考虑插补器和控制信号通信死区延迟的影响。忽略这些因素可能会导致系统在加工条件发生变化时出现不稳定或振荡。本文开发了一个综合加工过程模型,该模型集成了插补、伺服驱动系统、切削模型和通信死区延迟。为了解决不同加工条件下的不同动态行为,如不同的切削深度,开发了一种自适应史密斯控制器。所提出的控制器集成了在线参数估计器和史密斯预测器。估计参数反映了切削过程的动态,包括刀具磨损和系统不确定性的影响。Smith 预测器结构用于解决通信死区时间延迟问题,而这在之前的研究中被忽视了。自适应史密斯控制器的性能在具有三种不同切削深度的工件上得到了实验验证。与传统的比例积分控制器或史密斯预测器相比,自适应史密斯控制器可以调整进给速度,以保持恒定的扭矩,减少振荡。与不受控制的情况相比,建议的控制结构缩短了 10.5% 的加工时间。
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引用次数: 0
Influence of tool wear on geometric surface modeling for TC4 titanium alloy milling 刀具磨损对 TC4 钛合金铣削几何表面建模的影响
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2024-09-24 DOI: 10.1016/j.jmapro.2024.09.070
Xinyang Jiang , Jinfu Ding , Chengwu Wang , Ling Hong , Weifeng Yao , Wei Yu
Addressing the insufficient accuracy of milling surface roughness prediction model, the formation causes of different roughness were analyzed, and a surface roughness prediction model which takes tool wear into account was established based on an improved Z-MAP algorithm. Combining tool geometry and tool wear morphology, a mathematical model of surface profile was built; And the motion trajectory equations of the milling cutter teeth were established via machining kinematics. The servo rectangular encirclement and Newton iterative method were adopted to improve the Z-MAP algorithm. Combining the Z-MAP algorithm with the insert motion trajectory equations, the values at different height coordinates of the workpiece grid nodes were obtained, allowing numerical simulation of workpiece surface geometry and analysis of the effect of cutting trajectory overlap on the machined surface morphology. TC4 titanium alloy milling experiment was conducted to validate the simulation model. The simulated surface roughness Sa exhibited significant deviation from experimental values before tool wear, with a maximum error of 53.08 %. Nevertheless, the simulated values of Sa were closer to experimental values after tool wear, with a maximum error of 15.45 % and a minimum of only 3.07 %. Additionally, the predicted results for the bearing length ratio Rmr(c) were consistent with experimental values. The mathematical model for surface roughness taking tool wear into account effectively predicted the shape profile and surface roughness of the machined surface, providing theoretical guidance and technical support for practical production.
针对铣削表面粗糙度预测模型精度不足的问题,分析了不同粗糙度的形成原因,并基于改进的 Z-MAP 算法建立了考虑刀具磨损的表面粗糙度预测模型。结合刀具几何形状和刀具磨损形态,建立了表面轮廓数学模型;并通过加工运动学建立了铣刀齿的运动轨迹方程。采用伺服矩形包围法和牛顿迭代法改进了 Z-MAP 算法。将 Z-MAP 算法与刀片运动轨迹方程相结合,得到了工件网格节点不同高度坐标上的数值,从而可以对工件表面几何形状进行数值模拟,并分析切削轨迹重叠对加工表面形貌的影响。为验证模拟模型,进行了 TC4 钛合金铣削实验。在刀具磨损之前,模拟表面粗糙度 Sa 与实验值存在显著偏差,最大误差为 53.08%。然而,刀具磨损后的模拟 Sa 值更接近实验值,最大误差为 15.45 %,最小误差仅为 3.07 %。此外,轴承长度比 Rmr(c) 的预测结果与实验值一致。考虑刀具磨损的表面粗糙度数学模型有效地预测了加工表面的形状轮廓和表面粗糙度,为实际生产提供了理论指导和技术支持。
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引用次数: 0
Topography prediction at boundaries between sub-regions in the 5-axis milling of Plexiglas based on dimension reduction method 基于尺寸缩减法的有机玻璃五轴铣削中子区域边界的形貌预测
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2024-09-24 DOI: 10.1016/j.jmapro.2024.09.071
Qiang Guo , Zonglin Liu , Yan Jiang , Yuwen Sun , Zi Yang , Wenbo Wang , Weisen Zhao , Cletus Okoye
Sub-regional milling has become an important machining method in the production of free-form surface parts. However, due to complex tool paths, irregular surface topography can occur at the region boundaries, which in turn affects the performance of the part such as the light transmission, optical distortion and mechanical strength of non-metallic transparent material etc. It is vital for manufacturers and researchers to study the forming mechanism of topography at boundaries and then to control it to get the high quality of the machined surface. Therefore, this paper thoroughly investigates the formation of surface topography at the boundary of sub-regions in the five-axis machining process. First, the boundaries of sub-regions are classified. Simultaneously, swept surfaces of the cutting edge, taking into account the process parameters and tool path, are constructed. Then, the surface topography is calculated using an improved model based on dimension reduction theory. Furthermore, through simulation and experiments, the predicted surface topographies agree well with the measured ones. Finally, some conclusions are listed and the method in this paper can provide a reliable basis for manufacturing high-quality parts.
次区域铣削已成为生产自由曲面零件的一种重要加工方法。然而,由于刀具路径复杂,区域边界会出现不规则的表面形貌,进而影响零件的性能,如非金属透明材料的透光率、光学畸变和机械强度等。对于制造商和研究人员来说,研究边界形貌的形成机理并加以控制以获得高质量的加工表面至关重要。因此,本文对五轴加工过程中子区域边界表面形貌的形成进行了深入研究。首先,对子区域的边界进行分类。同时,考虑到加工参数和刀具路径,构建切削刃的扫掠表面。然后,利用基于降维理论的改进模型计算表面形貌。此外,通过模拟和实验,预测的表面形貌与测量的表面形貌非常吻合。最后,列出了一些结论,本文中的方法可为制造高质量零件提供可靠的依据。
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引用次数: 0
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